An acoustic emission-based method for determining contact between a tool and workpiece at the microscale

Keith A. Bourne; Martin B.G. Jun; Shiv G. Kapoor; Richard E. DeVor

doi:10.1115/1.2917285

An acoustic emission-based method for determining contact between a tool and workpiece at the microscale

Keith A. Bourne, Martin B.G. Jun, Shiv G. Kapoor, Richard E. DeVor

Mechanical Science and Engineering

Research output: Contribution to journal › Article › peer-review

Abstract

An acoustic emission-based touch-off detection system has been developed to determine contact between a rotating microtool and a workpiece surface with micron-level accuracy. The system has been implemented on an existing three-axis microscale machine tool. The system has been tested with microendmills as small as 50 μm in diameter and microdrills as small as 254 μm in diameter. The accuracy of the system has been found to depend on tool geometry and workpiece surface characteristics and is generally on the order of 1 μm. An analytical model has been constructed to predict touch-off detection error. The calibrated model has been shown to predict surface overshoot and undershoot trends quite well. Simulations have shown that touch-off error is dominated by part surface roughness.

Original language	English (US)
Pages (from-to)	311011-311018
Number of pages	8
Journal	Journal of Manufacturing Science and Engineering
Volume	130
Issue number	3
DOIs	https://doi.org/10.1115/1.2917285
State	Published - Jun 2008

ASJC Scopus subject areas

Control and Systems Engineering
Mechanical Engineering
Computer Science Applications
Industrial and Manufacturing Engineering

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abstract = "An acoustic emission-based touch-off detection system has been developed to determine contact between a rotating microtool and a workpiece surface with micron-level accuracy. The system has been implemented on an existing three-axis microscale machine tool. The system has been tested with microendmills as small as 50 μm in diameter and microdrills as small as 254 μm in diameter. The accuracy of the system has been found to depend on tool geometry and workpiece surface characteristics and is generally on the order of 1 μm. An analytical model has been constructed to predict touch-off detection error. The calibrated model has been shown to predict surface overshoot and undershoot trends quite well. Simulations have shown that touch-off error is dominated by part surface roughness.",

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AU - Kapoor, Shiv G.

AU - DeVor, Richard E.

PY - 2008/6

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N2 - An acoustic emission-based touch-off detection system has been developed to determine contact between a rotating microtool and a workpiece surface with micron-level accuracy. The system has been implemented on an existing three-axis microscale machine tool. The system has been tested with microendmills as small as 50 μm in diameter and microdrills as small as 254 μm in diameter. The accuracy of the system has been found to depend on tool geometry and workpiece surface characteristics and is generally on the order of 1 μm. An analytical model has been constructed to predict touch-off detection error. The calibrated model has been shown to predict surface overshoot and undershoot trends quite well. Simulations have shown that touch-off error is dominated by part surface roughness.

AB - An acoustic emission-based touch-off detection system has been developed to determine contact between a rotating microtool and a workpiece surface with micron-level accuracy. The system has been implemented on an existing three-axis microscale machine tool. The system has been tested with microendmills as small as 50 μm in diameter and microdrills as small as 254 μm in diameter. The accuracy of the system has been found to depend on tool geometry and workpiece surface characteristics and is generally on the order of 1 μm. An analytical model has been constructed to predict touch-off detection error. The calibrated model has been shown to predict surface overshoot and undershoot trends quite well. Simulations have shown that touch-off error is dominated by part surface roughness.

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An acoustic emission-based method for determining contact between a tool and workpiece at the microscale

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